Compartmentalization system for industrial totes and compartmentalizable totes

ABSTRACT

A compartmentalization system for an industrial tote includes a base, side walls, which include recesses for retaining bins within the tote and end walls. The tote may include eight recesses in each side wall for receiving a pair of inserts on a bin. The bins typically include two or four tabs. The bins that are used with the tote system include a base opposed side walls and end walls that define the interior of the bin. Typically, a lip formed at the top of the side and end walls to improve strength and stability. The tabs are formed on the exterior of at least one side wall. The tab is inserted into the recess in the tote. Each tab includes a riser that is substantially normal to the sidewall and a tab formed at the end of the riser so that the tab is spaced apart from the sidewall.

CLAIM OF PRIORITY

This application is Continuation in Part of U.S. Application 61/557,168, filed Nov. 8, 2011 entitled “COMPARTMENTALIZATION SYSTEM FOR INDUSTRIAL TOTES AND COMPARTMENTALIZABLE TOTES” and having Travis Shamp and Albert Kobilarcik as inventors. All aspects of Application 61/557,168 are hereby incorporated by reference.

BACKGROUND

Bins and bin systems are often used in industrial assembly. Often the bins filled with a number of parts and are moved along a conveyor from one location to the next. A large installed base of conveyor systems exists. The bins typically carry a single part or loose boxes of parts so that it is difficult to efficiently move parts through the conveyor system. Such bin conveyors are shown in U.S. Pat. No. 7,954,627 entitled “Bin Transporter System” showing Brian C. Weed et al. as inventors. Another patent showing such a conveyor system is U.S. Pat. No. 7,809,467 entitled “System and Method for order Picking of Articles into Order Containers” showing Gerhard Schaefer as inventor.

SUMMARY

In accordance with embodiments of the present invention, a compartmentalization system for industrial totes and compartmentalized totes and bins therefor are presented. The tote of the present invention include a base, side walls, which include recesses for retaining bins within the tote and end walls. As shown, the tote of the present invention includes a base, a first wall and a second side wall, each of side walls including a plurality of recesses for retaining a bin insert within the tote; and first and second end walls, the base, side walls and end walls defining a tote interior. Also disclosed is a bin for use in a compartmentalizable tote system, having a base; side walls; end walls forming a bin interior and a tab formed on the exterior of at least a first side wall, the tab being suitable for insertion into a recess formed in a first sidewall of a compartmentalizable tote system.

BRIEF DESCRIPTION OF THE DRAWINGS

A more complete appreciation of the invention and the many embodiments thereof will be readily obtained as the same becomes better understood by reference to the following detailed description when considered in connection with the accompanying drawings, wherein:

FIG. 1 illustrates an isometric view of the tote system with inserted bins of the present invention;

FIG. 1A illustrates an isometric, cross sectional view, in detail of the inserted bin retention system;

FIG. 2 illustrates an isometric view of the tote system of the present invention, without the inserted bins;

FIG. 2A illustrates a plan view of the tote system of the present invention, showing molded fixtures in the sidewall of the tote;

FIG. 3 illustrates an isometric view of bin inserts in accordance with the present invention;

FIG. 3A illustrates a cross sectional view of a bin insert in accordance with the present invention;

FIG. 3B illustrates a plan view of a bin insert in accordance with the present invention;

FIG. 3C illustrates an isometric view of a bin insert in accordance with the present invention;

FIG. 3D illustrates an plan view of a bin insert in accordance with the present invention;

FIG. 3E illustrates an elevational view of a bin insert in accordance with the present invention;

FIG. 4 illustrates an isometric view of a tote in an alternate embodiment of the present invention;

FIG. 5 illustrates an isometric view of the bottom of a tote in an alternate embodiment of the present invention.

FIG. 6 illustrates an isometric view of a tote with dividers inserted in an alternate embodiment of the present invention.

FIG. 7 illustrates an isometric view of a tote in another alternate embodiment of the present invention.

FIG. 8 illustrates an isometric view of a tote with dividers inserted in an alternate embodiment of the present invention.

DETAILED DESCRIPTION

The present invention will now be described with occasional reference to the specific embodiments of the invention. This invention may, however, be embodied in different forms and should not be construed as limited to the embodiments set forth herein. Rather, these embodiments are provided so that this disclosure will be thorough and complete, and will fully convey the scope of the invention to those skilled in the art.

Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this invention belongs. The terminology used in the description of the invention herein is for describing particular embodiments only and is not intended to be limiting of the invention. As used in the description of the invention and the appended claims, the singular forms “a,” “an,” and “the” are intended to include the plural forms as well, unless the context clearly indicates otherwise.

Unless otherwise indicated, all numbers expressing quantities of ingredients, properties such as molecular weight, reaction conditions, and so forth as used in the specification and claims are to be understood as being modified in all instances by the term “about.” Accordingly, unless otherwise indicated, the numerical properties set forth in the specification and claims are approximations that may vary depending on the desired properties sought to be obtained in embodiments of the present invention. Notwithstanding that the numerical ranges and parameters setting forth the broad scope of the invention are approximations, the numerical values set forth in the specific examples are reported as precisely as possible. Any numerical values, however, inherently contain certain errors necessarily resulting from error found in their respective measurements.

A compartmentalizable tote system is shown in FIG. 1 and FIG. 1A. The tote system includes a tote and one or more bins that may be secured within the tote. As shown in FIG. 1 and FIG. 1A the tote system may include a number of bins of different sizes and shapes. The bins are typically secured within the tote by a tab system on the side walls. As shown in FIG. 1, a tote 10 is provided with side walls 12 that may contain, a half-sized bin insert 22, a quarter-size bin insert 26 and two eighth-size bin inserts 28. The bin inserts may optionally include handles 24. The tote 10 may include a reinforcing rim 30 and a secondary rim 30 a formed on the upper portion of sidewalls 12 and a lower rim 34. Also included on sidewalls 12 are vertical tote reinforcements 36 and rim reinforcements 32 as well as a lower rim 34. The various bin inserts 22, 26, 28 may be used in any combination based on the needs of the facility using the totes.

The bin insert retaining system is shown in FIG. 1A, first and second tote sidewalls 12 include recesses for retaining bin inserts within the tote. The bin insert may include any number of recesses in each side wall. Preferably, the recesses 50, 52 are paired so each pair of recesses receives a pair of inserts on a bin 28. A second type of recess 64 may be provided for the insertion of divider walls (as shown in FIG. 6). Bin insert 28 includes side walls 28 a, 28 b, 28 c, 28 d and sidewalls 28 a and 28 c may include stack ribs 54. Stack ribs 54 are provided to inhibit the jamming of empty bin inserts 28 when stacked. The bin insert 28 also includes at least one retaining tab 50, 52 each having a spacer 84 that displaces tab 50, 52 from sidewall 28 d of bin insert 28. While tabs 50, 52 are shown turning to opposite sides they tab 52 may be of any suitable configuration, such as toward the exterior of the bin insert, toward the interior of the bin insert or spacer 84 may be located toward the center of tabs 50, 52 so that no apparent left or right turn is present. Tabs 50, 52 are received in slots 60, 62. Each slot 60 includes a front wall 60 a, side wall 60 c, back wall 60 d and distal wall 60 b. The walls 60 a, 60 b, 60 c and 60 d enclose slot 60, which receives the tab 50 while spacer 84 fits between front wall 60 a and side wall 60 c. Similarly, as shown walls 62 a, 62 b, 62 c and 62 d are formed in tote wall 12 to receive tab 52. A second configuration for a slot 64 in sidewall 12 a is shown in FIG. 1A in which the groove 64 is defined by two front walls 60 a, side walls 60 b, 60 c and a back wall 60 d. Reinforcing rim 30 and secondary rim 30 a formed on the upper portion of sidewalls 12 and rim reinforcements 32 provide a stiff and rugged tote for the bins.

The tote 10 is shown in FIG. 2, the tote includes sidewalls 12 having recesses 60, 62 for retaining bin inserts within the tote. The sidewalls 12 and sidewalls 12 a include slots 64 for retaining dividers 94 (as shown in FIG. 6). The bin insert may include any number of recesses 60, 62 or slots 64 in each side wall. Tote 10 includes reinforcing rim 30 and secondary rims 30 a, 30 b formed on the upper portion of sidewalls 12 and rim reinforcements 32 provide a stiff and rugged tote for the bins. Walls 12, 12 a are formed with vertical structural beams 36 between upper rims 30, 30 a, 30 b, and lower rim 34. The base of the tote includes channels 64 that receive tote dividers. The base also may include channel features 79 that define base sections 74 on which the internal bins rest. Preferably the internal bins include a lower lip that mates with the step down features 79 to inhibit movement of the bins within tote 10.

The side of tote 10 is shown in FIG. 2A. As with FIG. 2, the tote includes sidewalls 12 having recesses 60, 62 for retaining bin inserts within the tote. The sidewall 12 includes reinforcing rim 30 and secondary rims 30 a, 30 b formed on the upper portion of sidewalls 12 and rim reinforcements 32 and vertical structural beams 36 between upper rims 30, 30 a, 30 b, and lower rim 34. The base of tote 10 is typically smaller than the inner edge of the rim 30 so that multiple totes may be stacked vertically.

Three internal bins 22, 26, 28 are shown in FIG. 3. The bins 22, 26, 28 typically include two or four tabs 50, 52 depending on the size of the bin. While it may be preferable to have tabs on opposite sides of half size bin 22 it is not necessary to maintain a stable fit. It is also possible to manufacture bins of any size and that included eight tabs or more tabs. Typically at least one handle 24 is molded into the bins 22, 26, 28.

FIG. 3A shows a bin 28 including base 28 c, side walls 28 a, 28 b and upper rim 80. The upper rim 80 and sidewall 28 a are integrally formed with tab 50. Preferably, tab 50 is spaced apart from sidewall 28 a by spacer 84 and an upper reinforcement 82. The gap between tab 50 and sidewall 28 a is preferably slightly greater than the thickness of front wall 62 a of slot 60 (as shown in FIG. 1A). The tab 50 is releasably retained within slot 60.

As shown in FIG. 3B, the bin 28 may include base 28 c and side walls 28 a, 28 b, 28 e, one or more handles 24 and one or more tabs 50, 52. One suitable shape for the tabs 50, 52 is trapezoidal. The trapezoidal shape being wider at the top and tapering to a narrower width at the bottom provides for easier insertion of the bin and improved stability of the bin once installed. Each tab 50, 52 include may include a projection 50 b and an arcuate section 50 a formed in rim 80 that form a stop so that tabs 50, 52 do not jam into their respective slots.

As shown in FIG. 3C, the bin 26 may include side walls 26 a, 26 b, 26 d, 26 e, one or more handles 24 and one or more tabs 50, 52 formed in rim 80. One suitable shape for the tabs 50, 52 is trapezoidal. The quarter size bin 26 will generally include two pairs of tabs 50, 52 for secure retention within the tote.

As shown in FIG. 3D, the quarter sized bin 26 may include side walls 26 a, 26 b, 26 e, base 28 c, one or more handles 24 and one or more tabs 50, 52 formed in rim 80. As discussed above, with respect to FIG. 3B, one suitable shape for the tabs 50, 52 is trapezoidal. Each tab 50, 52 include may include a projection 50 b and an arcuate section 50 a formed in rim 80 that form a stop so that tabs 50, 52 do not jam into their respective slots. The use of two pairs of tabs 50, 52 provide sufficient stability when inserted. FIG. 3E shows a top view of bin 26 as shown in FIG. 3D, showing the position of handles 24 formed in rim 80 over tabs 50, 52. Also shown is base 28 c.

An alternate embodiment of the tote 10 is shown in FIG. 4. The tote includes sidewalls 12 having recesses 60, 62 for retaining bin inserts within the tote. The sidewalls 12 and sidewalls 12 a include slots 64 for retaining dividers 94 (as shown in FIG. 6). The bin insert may include any number of recesses 60, 62 or slots 64 in each side wall. Tote 10 includes reinforcing rim 30 and secondary rims 30 a, 30 b with rim reinforcements 32 formed on the upper portion of sidewalls 12, 12 a. Rim reinforcements 32 interconnecting rims 30, 30 a, 30 b provide a stiff and rugged tote for the bins. Slots 64 are formed in side wall 12 as are rim reinforcing members 36. Walls 12, 12 a are formed with vertical structural beams 36 between upper rims 30, 30 a, 30 b, and lower rim 34. The base of the tote includes channels 64 that receive tote dividers and define base step down features 79 and base sections 74 on which the internal bins rest.

FIG. 5 shows the alternate embodiment of the tote 10 as shown in FIG. 4. The tote includes sidewalls 12 having recesses 60, 62 for retaining bin inserts within the tote. The sidewalls 12 and sidewalls 12 a include slots 64 for retaining dividers 92, 94 (as shown in FIG. 6). The tote may include any number of recesses 60, 62 or slots 64 in each side wall. Tote 10 includes reinforcing rim 30 and secondary rims 30 a, 30 b with rim reinforcements 32 formed on the upper portion of sidewalls 12, 12 a. Slots 60, 62 are formed in side wall 12 as are rim reinforcing members 36. Walls 12, 12 a are formed with vertical structural beams 36 between upper rims 30, 30 a, 30 b, and lower rim 34. The base of the tote includes channels 64 that receive tote dividers and define base step down features 79 and base sections 74 on which the internal bins rest. Dividers 92, 94 are inserted into slots 64 to form a divided tote.

FIG. 6 shows the tote includes sidewalls 12 having recesses 60, 62 for retaining bin inserts within the tote. The sidewalls 12 and sidewalls 12 a include slots 64 for retaining dividers 94. The bin insert may include any number of recesses 60, 62 or slots 64 in each side wall. Tote 10 includes reinforcing rim 30 and secondary rims 30 a, 30 b with rim reinforcements 32 formed on the upper portion of sidewalls 12, 12 a. Rim reinforcements 32 interconnecting rims 30, 30 a, 30 b provide a stiff and rugged tote for the bins. Slots 64 are formed in side wall 12 as are rim reinforcing members 36. Walls 12, 12 a are formed with vertical structural beams 36 between upper rims 30, 30 a, 30 b, and lower rim 34. The base of the tote includes channels 64 that receive tote dividers and define base step down features 79 and base sections 74 on which the internal bins rest.

Yet another embodiment of the invention is shown in FIG. 7 and FIG. 8 in which the tote 100 includes sidewalls 112 and sidewalls 112 a include slots 164 for retaining dividers 180. The tote 100 may include any number of slots 164 in each side wall 112, 112 a. Tote 100 includes reinforcing rim 130 and secondary rims 130 a,130 b with rim reinforcements 132 formed on the upper portion of sidewalls 112, 112 a. Slots 164 are formed in side wall 112 as are rim reinforcing members 132. Walls 112, 112 a are formed with vertical structural beams 136 between upper rims 130, 130 a, 130 b, and lower rim 134. The base of the tote includes channels 164 that receive tote dividers 180, 182 and define base sections 174.

The totes and bins may be formed by any suitable method typically thermoforming, injection molding, blow molding and rotocasting are used for totes and bins.

The present invention should not be considered limited to the specific examples described herein, but rather should be understood to cover all aspects of the invention. Various modifications, equivalent processes, as well as numerous structures and devices to which the present invention may be applicable will be readily apparent to those of skill in the art. Those skilled in the art will understand that various changes may be made without departing from the scope of the invention, which is not to be considered limited to what is described in the specification. 

What is claimed is:
 1. A tote for a compartmentalization system, comprising: a base; first and second side walls, each of side walls including a plurality of recesses for retaining a bin insert within the tote; and first and second end walls, the base, side walls and end walls defining a tote interior.
 2. The tote of claim 1, wherein each recess comprises: a first side surface proximate the tote interior; a second side surface distal to the tote interior; and edge surfaces between the first and second side surfaces, whereby the first and second side surfaces and the edge wall define the recess.
 3. The tote of claim 1, further comprising: a first side surface proximate the tote interior; a second side surface distal to the tote interior; and edge surfaces between the first and second side surfaces, whereby the first and second side surfaces and the edge wall define a generally trapezoidal recess.
 4. The tote of claim 3, further comprising: a channel in the first side surface proximate the tote interior; and edge surfaces between the first and second side surfaces, whereby the first and second side surfaces and the edge wall define the recess.
 5. The tote of claim 3, further comprising: a plurality of recesses in each side wall; and a plurality of channels in the first side surface proximate the tote interior.
 6. The tote of claim 3, wherein the recesses are tapered from top to bottom such that the bottom is narrower than the top.
 7. The tote of claim 3, wherein the recesses are generally trapezoidal.
 8. The tote of claim 3, further comprising: eight recesses in each side wall, the recesses being grouped in pairs such that each pair of recesses receives a pair of inserts on a bin suitable for being received within the tote.
 9. The tote of claim 1, wherein the tote is formed by a method selected from the group consisting of thermoforming, injection molding, blow molding and rotocasting.
 10. A bin for use in a compartmentalizable tote system, comprising: a base; first and second side walls; first and second end walls, the base, side walls and end walls defining a bin interior. a tab formed on the exterior of at least a first side wall, the tab being suitable for insertion into a recess formed in a first sidewall of a compartmentalizable tote system.
 11. The bin of claim 10, further comprising a lip formed at the top of the first sidewall.
 12. The bin of claim 10, further comprising a lip formed at the top of the side and end walls.
 13. The bin of claim 10, wherein the tab comprises: a riser, substantially normal to the first sidewall; a tab section formed with the riser and spaced apart from the first sidewall.
 14. The bin of claim 13, wherein the tab section is tapered from the top portion to the bottom portion.
 15. The bin of claim 10, further comprising a plurality of tabs, each tab comprising: a riser, substantially normal to the first sidewall; a tab section formed with the riser and spaced apart from the first sidewall.
 16. The bin of claim 15, wherein the tab section is generally trapezoidal.
 17. A compartmentalizable tote and bin system, comprising: a tote having: a tote base; a first tote sidewall including a plurality of recesses for retaining a bin insert within the tote; and a second tote sidewall; first and second tote end walls, the tote base, the tote side walls and tote end walls defining an tote interior; the first tote sidewall having an interior surface and an exterior surface with edge surfaces between the interior and exterior surfaces, defining a recess; and a bin having: a bin base; first and second bin side walls; first and second bin end walls, the bin base, bin side walls and bin end walls defining a bin interior. at least one tab formed on the exterior of at least a first bin side wall, the tab being suitable for insertion into the tote recess.
 18. The compartmentalizable tote and bin system, of claim 17, wherein the tabs comprise: a riser, substantially normal to the first sidewall; a trapezoidal tab section formed with the riser and spaced apart from the first sidewall.
 19. The compartmentalizable tote and bin system, of claim 17, further comprising a plurality of recesses each having: a channel in the interior surface; and edge surfaces between the first and second side surfaces, whereby the first and second side surfaces and the edge wall define a trapezoidal recess.
 20. The compartmentalizable tote and bin system of claim 17, wherein the second tote sidewall includes a plurality of recesses for retaining a bin insert within the tote. 